Solar collector

ABSTRACT

A solar collector comprising an array of solar cells, each of which is spaced-apart from a subset of solar cells adjacent thereto, defining a hiatus therebetween; a first substrate disposed to cover the array of solar cells; and a second substrate disposed to cover the array of solar cells, with the array begin position between the first and second substrates, with a plurality of throughways, each of which extends from an aperture in the first substrate, traversing the hiatus and terminating in an opening in the second substrate.

BACKGROUND OF THE INVENTION

The present invention generally relates to solar panels and more particularly to a solar collector exposed to fluid streams.

Solar power has been viewed by many as a highly desirable energy resource, because it may be readily used to generate thermal and electrical energy. For example, a solar collector may collect thermal energy from the sun and direct the same to a desired system to increase the thermal energy of a component thereof, e.g., such as fluids that may include water, oil and the like. A solar collector employing a transducer, such as a photovoltaic device, may convert energy from the sun into electricity. By arranging solar collectors in arrays, power plants have been developed that generate vast amounts of electricity.

As the arrays increase in size, however, the potential for the structural integrity of the same to be compromised increases. This may be a function of both the materials from which the array is fabricated, as well as, the environment in which the array is disposed.

Therefore, a need exists to increase the structural integrity of a solar collector.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a solar collector comprising an array of solar cells, each of which is spaced-apart from a subset of solar cells adjacent thereto, defining a hiatus therebetween; a first substrate is disposed to cover the array of solar cells. A second substrate is disposed to cover the array of solar cells, with the array being positioned between the first and second substrates. A plurality of throughways is provided. Each of the throughways extends from an aperture in the first substrate, traversing the hiatus and terminating in an opening in the second substrate. In one embodiment, a sub-portion of the throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to the aperture with a radius greater than a radius of a remaining portions thereof. These and other embodiments are discussed further below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the present invention;

FIG. 2 is a detailed view of an array of solar cells shown in FIG. 1, in accordance with the present invention;

FIG. 3 is cross-sectional view of the invention shown in FIG. 2, taken along lines 3-3; and

FIG. 4 is a throughway shown in FIG. 3, in accordance with an alternate embodiment of the present invention;

FIG. 5 is a throughway shown in FIG. 4, in accordance with a second alternate embodiment of the present invention;

FIG. 6 is a throughway shown in FIG. 4, in accordance with a third alternate embodiment of the present invention; and

FIG. 7 is a throughway shown in FIG. 3, in accordance with a fourth alternate embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 a solar collector 10 includes multiple arrays 12 of solar cells 14. Collector 10 includes a frame 16 that is disposed on a stand 18 and holds multiple arrays 12 together. Typically, array 12 is disposed so as to allow the sun 20 to impinge upon solar cells 14. The energy collected may then be transported to a desired system 22 using suitable conduits 24 coupled between array 12 and system 22. Were solar collector 10 employed to generate thermal energy, conduits would be pipes through which a fluid passed and system would be a suitable device to use the heat fluid, e.g., a hot water storage container. In the case of a generation of electrical energy, conduits 24 would be electrical wires and system 22 may be any suitable electrical storage device. For purposes of the present discussion, solar collector 10 is described as being employed to generate electrical energy.

Referring to both FIGS. 1 and 2, each array 12 includes multiple photovoltaic solar cells PVSCs 14 supported by a frame 26. PVSCs 14 may be formed using any suitable technology. Examples of the technology that may be employed to form PCVSCs 14 are copper-indium-gallium-selenium (CIGS), cadmium-telluride (CdTe), amorphous silicon (a-Si), and crystalline silicon silicon (Si). PVSCs 14 are placed in electrical communication with one another through an electrically conductive path, referred to as a tabbing ribbon 30, which is coupled to a collector (not shown) of each PVCs 14. Tabbing ribbons 30 are connected in common to a bus 32.

Referring to both FIGS. 2 and 3, PVSCs 14 are disposed between two substrates 34 and 36, at least one of which is transparent. Typically substrates 34 and 36 are formed from glass. Insulation material may be disposed between substrates 34 and 36, such as air, to provide thermal insulation. Alternatively, as shown, a shock absorbent material 38 may be placed between substrates 34 and 36 to encapsulate PVSCs 14. In the present example, material 38 is transparent ethylene vinyl acetate (EVA). Anti-reflective coating 40 may be coated onto one or both of substrates 34 and 36. As shown anti-reflective coating 40 is disposed on substrate 34 upon which sunlight is to impinge. Anti-reflective coating 40 is positioned so as to maximize the flux of sunlight propagating through substrate 34 to impinge upon PVSCs 14. Tabbing ribbons 30 conducts current generated by PVSCs 14 to bus 30 and are typically 2 mm in width. Bus 32 is typically 5 mm in width. Bus 32 conducts current between arrays 12 of collector 10 and ultimately to a junction box 42 that is ultimately transmitted to conduits 24, shown in FIG. 1. To that end, a segment of bus 32 extends through substrate 36.

Referring again to both FIGS. 2 and 3, to facilitate use of solar collector in a fluid stream, e.g., wind, a plurality of fluid passages is formed in each of substrates 34 and 36, shown as 44 and 46, respectively. Each of fluid passages 44 is in superimposition with one of fluid passages 46. In this manner, fluid impinging upon one or both of substrates 34 and 36 may traverse fluid passages 44 and 46, thereby reducing the wind load on array 12 and therefore collector 10. In the presence of material 38 a passageway 48 is formed therein that extends between fluid passages 44 and 46, defining a throughway 50. With this configuration, array 12 includes a plurality of throughways. Throughways 50 function to reduce load upon array 12 due to fluid pressure, such as wind, impinging thereupon. Specifically, as the angle of incidence of the fluid impinging upon array 12 approaches a right angle, the load to which array 12 is subjected to increases. To reduce the load, it is desired that throughways 50 be present in array 12 and configured to maximize the probability of the fluid stream propagating therethrough as the angle of incidence approaches a right angle.

It is desired that material 38 function to insulate PVSCs 14 from fluid passing through passageway 48. To that end, fluid passages 44 and 46 and passageway 48 are disposed so as not to be in superimposition with PVSCs 14. As shown, each PVSC 14 of array 12 is spaced-apart from at least one adjacent PVSC 14, defining a hiatus 52 therebetween. In the present example each PVSC 14 of array is spaced-apart from PVSCs 14 adjacent thereto. It is desired that throughways 50 be present in hiatus 52.

Fluid passages 44 and 46 and passageway 48 are in superimposition with one another and are substantially cylindrical in shape and have matching diameters and, thereby, cross-sectional areas. In this fashion, throughway 50 has a constant diameter over a length thereof and is substantially radially symmetrically disposed about an axis 52.

Referring to FIG. 4 in accordance with another embodiment, throughway 150 is radially and symmetrically disposed about axis 152 and has a first portion 154 that extends from an aperture 156 in substrate 134 to a second portion 156 of throughway. First portion 154 has a radius 158 associated therewith that is greater than a radius 162 associated with second portion 156 of throughway 150. This is to take advantage of Bernoulli's principle to increase the velocity of fluid traversing throughway 150.

Referring to FIG. 5 in accordance with another embodiment, throughway 250 is radially and symmetrically disposed about axis 252 and has a first portion 254 that extends from an aperture 256 in substrate 234 and a second portion 264 that extends from an opening 266 in second substrate 236, with a third portion 238 extending therebetween. A third portion 238 extends between first portion 254 and second portion 264. A radius 270 of first portion 254 is substantially equal to a radius 272 of second portion 264, with a radius 274 of third portion 238 being less than radius 270 and radius 272.

Referring to FIG. 6 in another embodiment, in accordance with another embodiment, throughway 350 is radially and symmetrically disposed about axis 352 and has a first portion 354 that extends from an aperture 356 in substrate 334 and a second portion 364 that extends from an opening 366 in second substrate 336, with a third portion 338 extending therebetween. A radius 370 of first portion 354 varies over a length of first portion 354 to be greatest proximate to aperture and smallest proximate to third portion 338. Typically, radius of third portion 374 matches smallest size of radius 370. A radius 372 of second portion 354 matches radius 374 of third portion.

Referring to FIG. 7 in another embodiment, in accordance with another embodiment, throughway 450 is radially and symmetrically disposed about axis 452 and has a first portion 454 that extends from an aperture 456 in substrate 434 and a second portion 464 that extends from an opening 466 in second substrate 436, with a third portion 438 extending therebetween. A radius 470 of first portion 454 varies over a length of first portion 454 to be greatest proximate to aperture and smallest proximate to third portion 438. Typically, radius 474 of third portion 438 matches smallest size of radius 470. A radius 472 of second portion 454 varies over a length of second portion 454 to be greatest proximate to opening 466 and smallest proximate to third portion 438. Typically, radius of third portion 474 matches smallest size of radius 470.

Referring again to both FIGS. 2 and 3, fabrication of array 12 typically involves standard manufacturing techniques, such as by applying, to frame 16, tabbing ribbons 30 and bus 32 using any of a variety of techniques, such as solder-coating tabbing ribbons 30 and bus 32 and dipping the applying a flux thereto by dipping or spraying. Alternatively, the flux and/or a solder paste may be coated onto the individual PVCs 14 and the tabbing ribbon 30 and bus 32 applied thereto. Typically, PVCSs 14 are placed in electrical communication with tabbing ribbons 30 and this assembly is them deposited on substrate 34 with or with material 38, depending upon the application. After mounting to substrate 34 (is this done with an adhesive?), tabbing ribbons 30 are placed in electrical communication with bus 32, followed by mounting of substrate 36 thereto. Array 12 is then sealed with frame 26. Additional arrays 12 are mounted to an assembly and placed in electrical communication with one another.

It should be noted that the above description is not exhaustive. Many modifications may be made. For example, were gas present in array, a separate insert could be placed in the throughways to maintain a hermetic seal of array. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. 

1. A solar collector comprising: an array of solar cells, each of which is spaced-apart from a subset of solar cells adjacent thereto, defining a hiatus therebetween; a first substrate disposed to cover said array of solar cells; and a second substrate disposed to cover said array of solar cells, with said array being positioned between said first and second substrates, with a plurality of throughways, each of which extends from an aperture in said first substrate, traversing said hiatus and terminating in an opening in said second substrate.
 2. The solar collector as recited in claim 1 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to said aperture with a radius greater than a radius of remaining portions thereof.
 3. The solar collector as recited in claim 1 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to said aperture with a radius that varies over a length thereof to be greatest proximate to said aperture and larger than the radius of the remaining portions thereof and smallest proximate to the remaining portions.
 4. The solar collector as recited in claim 1 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a first portion disposed throughway proximate to said aperture, a second portion disposed proximate to said opening and a third portion disposed therebetween, with said first and second portions having a radius that is greater than a radius of said third portion.
 5. The solar collector as recited in claim 1 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a first portion disposed proximate to said aperture, a second portion disposed proximate to said opening and a third portion disposed therebetween, with said first portion having a radius that is varies over a length of said first portion to be greatest proximate to said aperture and smallest proximate to said third portion, said second portion having a radius that varies over a length of said second portion to be greatest proximate to said opening and smallest proximate to said third portion.
 6. The solar collector as recited in claim 1 wherein said solar cells are photovoltaic cells.
 7. The solar collector as recited in claim 1 wherein said first substrate is transparent to optical energy.
 8. The solar collector as recited in claim 1 wherein said first substrate is glass.
 9. The solar collector as recited in claim 1 wherein said first and second substrates are transparent glass.
 10. A solar collector comprising: an array of photovoltaic cells, each of which is spaced-apart from a subset of solar cells adjacent thereto, defining a hiatus therebetween; a glass substrate covering said array of solar cells; and a second substrate covering said array of solar cells, with said array being positioned between said glass substrate and said second substrate, with a plurality of throughways, each of which extends from an aperture in said glass substrate, traversing said hiatus and terminating in an opening in said second substrate.
 11. The solar collector as recited in claim 10 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to said aperture with a radius greater than a radius of remaining portions thereof.
 12. The solar collector as recited in claim 10 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to said aperture with a radius that varies over a length thereof to be greatest proximate to said aperture and larger than the radius of the remaining portions thereof and smallest proximate to the remaining portions.
 13. The solar collector as recited in claim 1 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a first portion disposed throughway proximate to said aperture, a second portion disposed proximate to said opening and a third portion disposed therebetween, with said first and second portions having a radius that is greater than a radius of said third portion.
 14. The solar collector as recited in claim 10 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a first portion disposed proximate to said aperture, a second portion disposed proximate to said opening and a third portion disposed therebetween, with said first portion having a radius that is varies over a length of said first portion to be greatest proximate to said aperture and smallest proximate to said third portion, said second portion having a radius that varies over a length of said second portion to be greatest proximate to said opening and smallest proximate to said third portion.
 15. The solar collector as recited in claim 10 wherein said second substrate is transparent glass.
 16. A solar collector comprising: an array of photovoltaic cells, each of which is spaced-apart from a subset of solar cells adjacent thereto, defining a hiatus therebetween; a first glass substrate covering said array of solar cells; and a second glass substrate covering said array of solar cells, with said array being positioned between said first and second glass substrates, with a plurality of throughways, each of which extends from an aperture in said glass substrate, traversing said hiatus and terminating in an opening in said second substrate.
 17. The solar collector as recited in claim 16 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to said aperture with a radius greater than a radius of remaining portions thereof.
 18. The solar collector as recited in claim 16 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a portion disposed proximate to said aperture with a radius that varies over a length thereof to be greatest proximate to said aperture and larger than the radius of the remaining portions thereof and smallest proximate to the remaining portions.
 19. The solar collector as recited in claim 16 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a first portion disposed throughway proximate to said aperture, a second portion disposed proximate to said opening and a third portion disposed therebetween, with said first and second portions having a radius that is greater than a radius of said third portion.
 20. The solar collector as recited in claim 16 wherein a sub-portion of said throughways are radially symmetrically disposed about an axis and have a first portion disposed proximate to said aperture, a second portion disposed proximate to said opening and a third portion disposed therebetween, with said first portion having a radius that is varies over a length of said first portion to be greatest proximate to said aperture and smallest proximate to said third portion, said second portion having a radius that varies over a length of said second portion to be greatest proximate to said opening and smallest proximate to said third portion. 